ATS CyberChiller Series - Manual (Page 3)

(©October, 2006)
CyberChiller Series Installation, Operation & Maintenance Manual
1.0 Introduction ....................................... 1-1
1.1 General ...................................................... 1-1
1.2 Product Description ................................... 1-1
1.2.1 Capabilities and Features .......................... 1-1
1.2.2 Application Ranges .................................... 1-1
1.2.3 General Design .......................................... 1-2
1.2.4 Safety Features ......................................... 1-3
1.3 Product Warranty ...................................... 1-4
1.4 Safety ........................................................ 1-6
1.4.1 General ...................................................... 1-6
1.4.2 Safety Summary ........................................ 1-6
2.0 Installation ......................................... 2-1
2.1 Receiving the Equipment. .......................... 2-1
2.2 Site Preparation ......................................... 2-1
2.3 Rigging ...................................................... 2-1
2.4 Mounting/Placement .................................. 2-1
2.4.1 Indoor Equipment ....................................... 2-2
2.4.2 Outdoor Equipment .................................... 2-2
2.4.3 Pump Package Installation (Water - Glycol
Systems .................................................... 2-2
2.4.4 Optional Equipment (Field Installed) .......... 2-2
2.4.4.1 Remote Display ......................................... 2-2
2.4.4.2 Remote Water Detector ............................. 2-2
2.5 Piping Connections .................................... 2-3
2.5.1 Process Supply Fluid Lines ....................... 2-3
2.5.2 Refrigerant ................................................. 2-3
2.5.2.1 Split Air Cooled Systems ........................... 2-3
2.5.2.2 Water/Glycol Fluid Cooled Systems .......... 2-4
2.5.3 Pump Package .......................................... 2-5
2.6 Utility Connections .................................... 2-5
2.6.1 Main Power ............................................... 2-5
2.6.2 Controls ..................................................... 2-7
2.6.3 Optional Equipment ................................... 2-7
2.6.3.1 Remote Water Detector ............................. 2-7
2.6.4 Interconnecting Field Wiring ....................... 2-7
2.6.4.1 Air-Cooled Split Systems
Remote Condenser .................................... 2-8
2.6.4.2 Glycol Systems with Outdoor Fluid Pump
Package .................................................... 2-8
2.7 System Settings and Adjustments ............. 2-9
TABLE OF CONTENTS
2.7.1 Chilled Water Supply Charging
Procedures (Evaporator Side) .................... 2-9
2.7.2 Outdoor Heat Exchanger Glycol Charging
Procedures .............................................. 2-10
2.7.3 R-22 Refrigerant Charging Procedures ...... 2-11
2.7.4 R-407C Refrigerant Charging Procedures .. 2-11
2.7.5 Low/High Pressure Limit Switch .............. 2-12
2.7.6 Head Pressure Controls ........................... 2-13
2.7.6.1 Air-Cooled Systems ................................. 2-13
2.7.6.2 Water/Glycol Cooled Systems ................. 2-13
2.7.7 Thermal Expansion Valve ......................... 2-13
2.7.8 Hot Gas Bypass ...................................... 2-13
2.8 Refrigerant Characteristics ....................... 2-14
2.8.1 Pressure/Temperature Settings ................ 2-14
2.8.2 Saturated Refrigerant Pressure Tables ..... 2-14
3.0 Start-Up/Commissioning .................. 3-1
3.1 Operation ................................................... 3-1
3.2 Step by Step Start-Up Instructions ............. 3-1
3.2.1 Operational Description .............................. 3-1
3.3 Microprocessor Controller
Programming ............................................. 3-2
4.0 Maintenance/Repairs ....................... 4-1
4.1 Periodic General Maintenance ................... 4-1
4.1.1 General ...................................................... 4-1
4.1.2 Compressor ............................................... 4-1
4.1.3 Outdoor Condenser/Fluid Cooler ................ 4-1
4.2 Troubleshooting ......................................... 4-2
4.3 Field Service .............................................. 4-5
4.3.1 Leak Detection .......................................... 4-5
4.3.2 Leak Repair ............................................... 4-5
4.3.3 Refrigerant Piping ...................................... 4-5
4.3.4 General Common Repairs/
Component Replacement ........................... 4-5
4.3.4.1 Compressor Failure ................................... 4-5
5.0 Product Support Group ................... 5-1
5.1 Technical Support ...................................... 5-1
5.2 Obtaining Warranty Parts .......................... 5-1
5.3 Obtaining Spare/Replacement Parts .......... 5-1
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